Conveying system

ABSTRACT

An apparatus for transporting articles includes a first transporter (e.g. a conveyor) for transporting articles in a line and a member that separates the articles in the line into groups and also removes the groups from the line while the articles continue to be transported.

TECHNICAL FIELD

[0001] This invention relates to the handling of containers in atransporter system.

BACKGROUND

[0002] Conveying systems are used in bottling plants, where emptybottles are filled with a liquid, such as a beverage. The filled bottlesare sealed, labeled, and packaged for distribution.

[0003] At the filling stage, the bottle is filled with juice at atemperature sufficiently high to sterilize both the juice and thebottle. After being filled, the bottle is sealed, for instance with aplastic cap, and transferred into a bottle cooler. Often, a stream ofbottles is fed single-file on a conveyor that moves them to a transferapparatus, which then moves the bottles onto a mass flow conveyorthrough the cooler. The bottles on the mass flow conveyor are massedtogether, i.e., are no longer in single file.

[0004] After cooling to approximately ambient temperature, the bottlescan be sent to subsequent areas of the bottling plant.

SUMMARY

[0005] In one aspect, the invention features an apparatus for firsttransporting articles such as beverage containers. The apparatusincludes a first transporter (e.g., a conveyor) for transportingarticles in a line and a member that separates the articles in the lineinto groups and also removes the groups from the line while the articlescontinue to be transported. “In a line”, as used herein, refers toarticles arranged in parallel that are being moved by the transportersin the parallel direction. “Groups”, as used herein, includes two ormore, for example, between 2 and 300, preferably between 6 and 70, andmore preferably between 12 and 30. Preferably, the articles aretransported in a single and/or continuous line.

[0006] In a preferred embodiment, the member is a rotator belt thatintersects the line of articles. The rotator belt may include, forexample, three to five wedges that separate the articles into the groupsand push the groups out of the line. The wedge may be flexible; eachwedge may be composed, for example, of separated elements of varyinglengths.

[0007] In other preferred embodiments, the apparatus can include: (1) ablocking member positioned to obstruct the articles; (2) a member forreceiving the group of articles from the transporter; and/or (3) asecond transporter for receiving and transporting the groups eitherdirectly from the first transporter or from the plate (if present).

[0008] The apparatus can be used, for example, to transport articlessuch as beverage containers. The beverage containers can be filled withbeverage and sterilized at elevated temperature while in the line. Theline often will be moving at a relatively high rate of speed during thefilling and sterilizing. Advantageously, the apparatus allows thecontainers in the line to be automatically divided into groups and movedfrom the line, for example, onto a mass flow conveyor that moves thecontainers into a cooler. The mass flow conveyor has a much slower speedthan the first transporter, and as a result the apparatus provides a wayto separate and transfer groups of containers from a line moving at arelatively high speed to a mass flow conveyor moving at a low speedwithout having to stop the first transporter or otherwise impede theflow of parallel flow of bottles to make the transfer.

[0009] In a second aspect, the invention features an apparatus includingthe first transporter and a rotator belt that includes wedges that pushgroups of articles from the line and/or separate the articles intogroups while the articles continue to be transported in the line.

[0010] In a third aspect, the invention features a method oftransporting articles. The method includes transporting a line ofarticles in a first direction and simultaneously separating a group ofthe articles from the line and transferring the group out of the linewhile the line continues to be transported in the first direction. Thearticles can be, for example, bottles, cans, containers, cartons, pies,loaves, or baked goods. The method may also include transporting thegroups in a second direction (for example, a direction that is between45° and 135°, relative to the first direction) in a mass flow onto, forexample, a cooler conveyor.

[0011] When the article is a rectangular bottle, in one embodiment thebottles are transported short-side first in the first direction. Theseparating and transferring may be carried out using the rotator beltwith wedges, and the depth of the wedge may be approximately the lengthof the short side.

[0012] In embodiments in which separated and transferred groups ofarticles are then transported in a second direction, the speed oftransport of the line in the first direction can be substantiallygreater than the speed of transport in the second direction. Forexample, the speed of transport in the first direction can be more than25 times the speed of transport in the second direction. The speed inthe first direction may be, for example, between 10 and 400 feet perminute (fpm), and the speed in the second direction may be, for example,between 2 and 30 fpm.

[0013] The details of one or more embodiments of the invention are setforth in the accompanying drawings and the description below. Otherfeatures, objects, and advantages of the invention will be apparent fromthe description and drawings, and from the claims.

DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a top plan view of a transfer apparatus, without thewedge profile conveyor and with the top to the cooler absent;

[0015]FIG. 2 is a top plan view of the apparatus in FIG. 1, with thewedge profile conveyor and bottles;

[0016]FIG. 3 is a top plan view of the apparatus in FIG. 1, takensubsequent in operation of the apparatus;

[0017]FIG. 4 is a side view of the apparatus in FIG. 1, without the endof the conveyor;

[0018]FIG. 5A is a top plan view of an alternative transfer apparatus;

[0019]FIG. 5B is a front view of an alternative transfer apparatus;

[0020]FIG. 6 is a top plan view of another alternative transferapparatus; and

[0021]FIG. 7 is a side view of alternative fingers.

DETAILED DESCRIPTION

[0022] Referring to FIGS. 1-4, a transfer apparatus 10 includes aninfeed conveyor 12, a wedge profile conveyor 14, and a mass flowconveyor 16. Infeed conveyor 12 carries bottles 18 in an infeeddirection 20. Mass flow conveyor 16 carries bottles 18 in an outflowdirection 22. Wedge profile conveyor 14 intersects the path of bottles18 traveling in direction 20 on infeed conveyor 12.

[0023] Wedge profile conveyor 14 transfers groups 24 of bottles 18 offinfeed conveyor 12 and toward mass flow conveyor 16. Wedge profileconveyor 14 separates bottles 18 into groups 24 of two or more.

[0024] Transfer apparatus 10 also includes dead plate 26 and row stop28. Dead plate 26 bridges a gap between infeed conveyor 12 and mass flowconveyor 16. Dead plate 26 receives groups 22 of bottles 18 that aremoved by wedge profile conveyor 14 off infeed conveyor 12.

[0025] Row stop 28 is rigidly attached to the frame of wedge profileconveyor 14 and is arranged to obstruct the path of bottles 18 on infeedconveyor 12. Row stop 28 blocks bottles 18 that are on infeed conveyor12, or on dead plate 26, from passing beyond the downstream end of deadplate 26 or beyond the downstream edge of the mass flow conveyor 16,relative to the flow of bottles. Transfer apparatus 10 aligns a group 24of bottles 18 against row stop 28 as part of the transfer of the group24 off infeed conveyor 12. Row stop 28 also prevents a downed bottle 18(for instance, one which may have been knocked over accidentally) fromrolling out of transfer apparatus 10.

[0026] Infeed conveyor 12 includes infeed drive wheel 30 connected toinfeed motor 32. Infeed conveyor 12 also includes infeed belt 34arranged in an endless loop, which passes around infeed drive wheel 30.Infeed motor 32 drives infeed drive wheel 30.

[0027] Infeed belt 34 is a tabletop chain. Bottles 18 rest on an uppersurface 36 of infeed belt 34. Infeed belt 34 has a low friction surface,allowing bottles 18 to slide without tipping or becoming scratched. Thelow friction of the surface also reduces back-pressure among the bottles18 when the bottles are blocked from traveling on infeed conveyor 12,for instance when bottles 18 are backed up against row stop 28.

[0028] Upper surface 36 is slightly inclined toward wedge profileconveyor 14, for example, at an angle of one or two degrees. The inclineof upper surface 36 causes bottles 18 to lean into contact with wedgeprofile conveyor 14.

[0029] Infeed conveyor 12 turns the path of bottles 18 at curve 38.After passing curve 38, bottles 18 travel in infeed direction 20. Infeeddirection 20 is approximately straight near wedge profile conveyor 14.

[0030] Bottles 18 (of the 64 ounce non-round size) are plastic and arefilled with juice. Each bottle 18 has a cross-section that isapproximately rectangular. Each bottle 18 is sealed with a cap. Bottles18 are approximately 10{fraction (5/16)} inches high, 3{fraction (7/32)}inches wide along a short side, and 4⅝ inches long along a long side.Bottles 18 are contoured to included vacuum panels and grips. Portionsof infeed conveyor 12 include guide rails that help keep bottles 18upright and oriented short-side first when moving in infeed direction20.

[0031] Wedge profile conveyor 14 includes wedge belt 40 that loops aboutdrive wheel 44 and idle wheel 46 such that interface region 48 of wedgebelt 40 intersects the path of bottles 18. Interface region 48 occursapproximately where wedge belt 40 is straight and faces mass flowconveyor 16. Transfer motor 42 drives drive wheel 44. When passingthrough interface region 48, wedge belt 40 travels in belt direction 49.

[0032] Wedge profile conveyor 14 includes three wedges 50. The length ofwedge 50 approximates the maximum length of a group 24 to be selected bywedge 50. The length of wedge 50 is slightly less than the width of massflow conveyor 16; for example, wedge 50 is approximately 10 feet long.Each wedge 50 includes a pushing face 52 and fingers 54 of differentlengths.

[0033] Fingers 54 are L-shaped. A base portion is upright and affixes towedge belt 40. All fingers 54 have similarly shaped base portions. Anextended portion extends horizontally away from wedge belt 40. Fingers54 vary in the lengths of their extended portions. Each finger 54 has apushing tip 56 at the end opposite the base portion. When viewed fromabove, the extended portions of fingers 54 have cross-sections that areapproximately rectangular on three consecutive sides, the second ofwhich is in contact with wedge belt 40. Pushing tip 56 of each finger54, i.e., the surface that contacts bottles 18, is rounded to reducefriction on, and interaction with, the bottles 18.

[0034] The relative position of adjacent fingers 54 can change whenwedge belt 40 flexes. The fingers 54 are separable from one another,such that when a portion of wedge belt 40 containing adjacent fingers 54travels around drive wheel 44 or idle wheel 46, the fingers 54 flareapart. However, when the same portion of wedge belt 40 is substantiallystraight (for example, within interface region 48), the adjacent fingers54 are closely spaced. More specifically, wedge belt 40 includes atiming belt that includes teeth 58 spaced at 20 mm intervals. Each tooth58 has multiple holes 60 for bolting a finger 54 to the tooth 58.Fingers 54 in a wedge 50 are bolted at regular intervals ofapproximately 1.5 inches. Each finger 54 has a width of about 1 inch.Each finger 54 is less than half as wide as a bottle 18. When adjacentfingers 54 are in a non-flared state, the gap between fingers isapproximately 0.5 inches. The shortest finger in a wedge 50 has almostno length in its extended portion; the extended portion of the longestfinger 54 has a length of about 4 and ⅝ inches. The difference betweenthe length of the longest finger 54 and the shortest finger 54approximates the width of a bottle 18 measured perpendicular to infeeddirection 20; for example, the short-side width of bottle 18 astransported on infeed conveyor 12.

[0035] Fingers 54 are formed UHMW (ultra-high molecular weight) plastic.Metal bolts 62 through the base of the finger rigidly affix the fingerto wedge belt 40.

[0036] Wedge belt 40 is drawn sufficiently taut between drive wheel 44and idle wheel 46 that interface region 48 is substantially planar aswedge belt 40 is driven. Retaining clips help keep wedge belt 40 aligneddespite downward force exerted by the weight of fingers 54.

[0037] Wedge profile conveyor 14 includes a frame that is movablerelative to infeed conveyor 12 along track 66. Hand cranks 68 and 69 areattached to threaded rods at opposing ends of wedge profile conveyor 14.Threaded rods join wedge profile conveyor 14 to infeed conveyor 12. Byrotating hand cranks 68 and 69, a human operator can adjust the distancebetween wedge profile conveyor 14 and infeed conveyor 12. In particular,this adjustment changes the relationship of pushing face 52 to offloadedge 70.

[0038] Infeed conveyor 12 has an offload edge 70. Offload edge 70presents a substantially straight profile when viewed from above.Pushing face 52 approximates the shape of offload edge 70.

[0039] Each wedge 50 has a wedge angle 72. When wedge 50 is on asubstantially straight portion of wedge belt 40, pushing face 52 issubstantially planar and wedge 50 has a substantially triangular profilewhen viewed from above.

[0040] Intersection angle 74 is the angle at which wedge belt 40 crossesthe infeed direction 20 in interface region 48, when viewed from above.Intersection angle 74 is approximately equal to wedge angle 72. Oneeffect of this approximate equality is that pushing face 52 isapproximately parallel to offload edge 70 when wedge 50 travels throughinterface region 48. Furthermore, wedge profile conveyor 14 ispositioned relative to the infeed conveyor 12 such that, when theleading tip of wedge 50 is approximately aligned opposite row stop 28,and when pushing face 52 is pushing a group 24 of bottles 18 off infeedconveyor 12, pushing face 52 places the centers of mass of bottles 18directly over offload edge 70.

[0041] Transfer apparatus 10 can be adjusted to various sizes of bottles18. An alignment of transfer apparatus 10 that places bottles 18 of afirst size at a given position on offload edge 70 may not place bottles18 of a different size at the same position on offload edge 70. Forexample, if a different bottle size has a different distance from itscenter of mass to its side that contacts pushing face 52, then thecenter of mass will reach offload edge 70 at a different location. Handcranks 68 and 69 can re-position wedge profile conveyor 14 relative toinfeed conveyor 12 such that pushing face 52 pushes groups 24 overoffload edge 70 at a desired location.

[0042] Dead plate 26 lies almost flush along infeed conveyor 12 alongoffload edge 70, for example at a distance of less than 0.125 inches.Dead plate 26 has an upper surface that inclines away from offload edge70, for example at an angle of six to seven degrees. There is a tradeoffin the choice of the angle of incline, since a steeper angle tends toclear bottles 18 from dead plate 26 faster, but too steep an incline cancause bottles 18 to topple. Dead plate 26 is inclined at approximatelythe steepest angle at which the described bottles 18 can be tiltedwithout toppling bottles 18.

[0043] The underside of dead plate 26 contacts the surface of mass flowconveyor 16. Dead plate 26 is kept in close contact with this surfaceunder elastic tension within dead plate 26. That is, dead plate 26 isbent upward slightly by mass flow conveyor 16.

[0044] Infeed conveyor 12 transports bottles 18 in a source direction 21before turning the flow of bottles 18 into infeed direction 20 at curve38. Curve 38 allows infeed conveyor to guide bottles 18 into interfaceregion 48, thereby avoiding putting bottles 18 in an area around idlewheel 46 where fingers 54 interact with bottles 18 inconsistently, dueto varying finger lengths and the flexing of wedge belt 40. Inparticular, when wedge belt 40 travels around idle wheel 46, each finger54 forms a moment arm. The pushing tip 56 develops a higher angularvelocity than the wedge belt 40 to which it is attached. Thus, thepushing tip 56 of a finger 54 on idle wheel 46 travels faster thanpushing tips 56 in interface region 48. When bottles 18 come intocontact with such higher-velocity fingers 54, the different velocityimparts a force that is higher, and in a different direction, than theforce imparted by fingers 54 in interface region 48. Fingers 54 roundingthe idle wheel 46 can “slap” the bottles 18. Since fingers 54 are ofprogressively longer lengths, the slapping effect increases for fingers54 toward the trailing end of each wedge 50. The variation in force dueto slapping can push bottles 18 out of alignment with one another andout of contact, at least temporarily, with fingers 54.

[0045] However, the region in which the slapping effect can occur islimited to the area around idle wheel 46 defined by the reach of thelongest finger 54 beyond wedge belt 40 for the portions of wedge belt 40that are in direct contact with idle wheel 46.

[0046] Transfer apparatus 10 also includes overflow table 76, photo eye78, and downed bottle dead plate 80. Overflow table 76 is positionedupstream of mass flow conveyor 16, relative to the flow of bottles 18.When more bottles arrive from infeed conveyor 12 than are removed byeither dead plate 26 or mass flow conveyor 16, or both, for instance dueto a blockage on mass flow conveyor 16, congestion occurs, causingbottles 18 to back up onto overflow table 76. Photo eye 78 detects thepresence of bottles on overflow table 76. Photo eye 78 notifies aprogrammable logic controller, which shuts down the flow of bottles 18into transfer apparatus 10.

[0047] Downed bottle dead plate 80 helps control downed bottles 18 in aregion between the end of the guide rails on infeed conveyor 12 and thearea in which wedge belt 40 overlaps infeed conveyor. Were downed bottledead plate 80 absent, a downed bottle 18 could roll into this region,when, for instance, the shortest fingers 54 of a wedge 50 were passingidle wheel 46. In this configuration, a temporary gap would existbetween wedge 50 and infeed conveyor 12—a gap which would close as wedgebelt 40 advances and the longer fingers 54 of wedge 50 sweep through. Adowned bottle 18 in this temporary gap could drop down and become jammedbetween wedge 50 and infeed conveyor 12 once the longer fingers 54arrive. Downed bottle dead plate 80, however, approximately extends theplane of the upper surface 36, eliminating the gap. When a downed bottle18 enters this region, downed bottle dead plate 80 supports the downedbottle 18 until the longer fingers 56 push the downed bottle 18 backonto infeed conveyor 12.

[0048] In use, infeed conveyor 12 transports a steady flow of bottles 18resting on upper surface 36 in infeed direction 20. The bottles 18 aretransported consecutively, in single-file order, such that their centersare approximately on an infeed line 82. The speed of transport can bebetween 100 and 800 bottles per minute, for instance. Interface region48 intersects infeed line 82. The motion of wedge belt 40 in beltdirection 49 brings a wedge 50 into interface region 48, where pushingface 52 contacts a group 24 of the bottles 18 arranged in infeed line82. The pushing face 52 selects a bottle 18 for membership in group 24if the bottle 18 is within the length of the wedge 50 from the front ofthe line 82. For example, for a steady flow of bottles in mutual contactalong line 82, approximately 26 bottles 18 can fit along the ten-footlength of each wedge 50.

[0049] The progress of wedge belt 40 causes the pushing face 52 of wedge50 to sweep across infeed conveyor 12. Pushing face 52 pushes group 24off infeed line 82 and toward offload edge 70. Pushing face 52 alignsgroup 24 in a row that conforms in shape to offload edge 70, such thatthe bottles 18 in group 24 each reach offload edge 70 at substantiallythe same time. In particular, the centers of mass of the bottles 18 ingroup 24 reach offload edge 70 at substantially the same time.

[0050] When the center of mass of a bottle 18 crosses offload edge 70,the bottle 18 tips from the incline of upper surface 36 (which tiltstoward wedge 50) to the incline of dead plate 26 (which tilts away fromwedge 50). Bottle 18 ceases to rest on infeed conveyor 12 and insteadtransfers to dead plate 26. After this transfer, infeed conveyor 12 nolonger conveys its force to bottle 18 in infeed direction 20. Frictionof bottle 18 upon dead plate 26 creates a braking force on the movementof the bottle 18.

[0051] Bottles 18 are also arrested by row stop 28. Wedge profileconveyor 14 is arranged so that pushing face 52 pushes its group 24toward a potential transfer location across offload edge 70 that isslightly (for example, less than a bottle length) downstream of row stop28, relative to infeed direction 20. Row stop 28 obstructs group 24before group 24 can reach the potential transfer location. When theforemost bottle 18 in group 24 contacts row stop 28, group 24 stacks upagainst row stop 28 and pushing face 52. This stacking causes group 24to close ranks into mutual contact while crossing offload edge 70 ontodead plate 26. This stacking also aligns groups 24 relative to oneother, since each group 24 becomes aligned relative to the row stop 28.

[0052] Row stop 28 is positioned sufficiently close to infeed conveyor12 and dead plate 26 that row stop 28 obstructs bottles 18 on infeedconveyor 12 and dead plate 26, including bottles 18 rolling on theirsides. However, row stop 28 does not obstruct wedges 50.

[0053] When group 24 is obstructed by row stop 28, wedge 50 continuesits motion, which can cause it to rub against obstructed group 24. Therounding of pushing tips 56 of fingers 54 reduces wear of wedge 50against bottles 18.

[0054] Bottles 18 in group 24 proceed down the incline of dead plate 26and toward mass flow conveyor 16. Bottles 18 are impelled down theincline by the force of gravity as well as by momentum from pushing face52. If any bottles 18 do not proceed across dead plate 26, a subsequentgroup 24 arriving off infeed conveyor 12 contacts such stray bottles 18from behind. If the subsequent group 24 is in contact with both straybottles 18 and pushing face 52, the force from pushing face 52 will pushboth subsequent group 24 and stray bottles 18 toward mass flow conveyor16. Eventually, even if gravity and momentum are not moving bottles 18across dead plate 26 and even if the number of bottles 18 on dead plate26 is initially sparse, enough subsequent groups 24 arrive to populatedead plate 26 and establish a chain of mutual contact between bottles 18that leads back to pushing face 52. In this case, the chain of contactallows pushing face 52 to push all bottles 18 on dead plate 26 towardmass flow conveyor 16.

[0055] Mass flow conveyor 16 receives bottles 18 from dead plate 26 andconveys them in outflow direction 22 at a speed of 4 fpm.

[0056] The rates of bottles 18 transported per minute by infeed conveyor12 and mass flow conveyor 16, respectively, depend on bottle dimensionsand the average gaps between bottles 18. The rate of bottles 18transported into transfer apparatus 10 by infeed conveyor 12 can be ashigh as the rate of bottles 18 removed from transfer apparatus 10 bymass flow conveyor 16.

[0057] When bottles 18 arrive on infeed conveyor 12 in approximatelycontinuous mutual contact, and when pushing face 52 is nearly as long asmass flow conveyor 16 is wide, transfer apparatus 10 selects groups 24that approximately span the surface of mass flow conveyor 16 andtransfers the groups 20 to mass flow conveyor 16.

[0058] The spacing between groups 24 on mass flow conveyor 16 is afunction of the speed of mass flow conveyor 16. When mass flow conveyor16 picks up groups 24 at a speed that keeps groups 24 mutually close onmass flow conveyor 16, and for sufficiently dense input of bottles 18,the groups 24 approximately cover the surface of mass flow conveyor 16.That is, the density of bottles 18 on mass flow conveyor 16 is close tooptimal.

[0059] Bottles 18 can arrive sporadically, for instance due to theremoval of some bottles 18 from the flow due to quality control. In thiscase, transfer apparatus 10 operates as described, although a givenoperation of pushing face 52 to select a group 24 might net fewerbottles 18 than the maximum possible number. Therefore, the density ofbottles 18 on mass flow conveyor 16 can decline for sporadic inputs.

[0060] Similarly, increasing the speed at which wedge belt 40 moves willcause each operation of pushing face 52 to encounter fewer bottles 18while select a group 24. The average population of a group 24 candecline in this way.

[0061] Other embodiments are within the claims. For example, althoughthe described embodiment conveys articles that are bottles, inalternative embodiments the articles could be containers (such as piecontainers), bread loafs, boxes, or bundles of products. Also, in thedescribed embodiment, each bottle 18 is a 64-ounce non-round container.In alternative embodiments, bottles 18 could be round. Bottles 18 couldbe a different size, for instance 48-ounce, or gallons.

[0062] Referring now to FIGS. 5A and 5B, in an alternative embodiment,wedge profile conveyor 84 transfers groups 24 of bottles 18 off infeedconveyor 12 and toward mass flow conveyor 16. Wedge profile conveyor 84separates bottles 18 into groups of two or more.

[0063] Wedge profile conveyor 84 is positioned to intercept bottles 18carried by infeed conveyor 12. Wedge profile conveyor 84 includeshorizontal idle wheel 84 a, horizontal drive wheel 84 b, and horizontalwedge belt 84 c, which is an endless loop belt wrapped around horizontalidle wheel 84 a and horizontal drive wheel 84 b. Horizontal drive wheel84 b drives horizontal wedge belt 84 c.

[0064] Wedge profile conveyor 84 includes three horizontal wedges 86affixed to horizontal wedge belt 84 c. The length of each horizontalwedge 86 approximates the maximum length of a group 24 to be selected byhorizontal wedge 86. The length of horizontal wedge 86 is slightly lessthan the width of mass flow conveyor 16; for example, horizontal wedge86 is approximately 10 feet long.

[0065] Each horizontal wedge 86 includes a pushing face comparable infunction to pushing face 52 of wedge 50. Each horizontal wedge 86 alsoincludes horizontal fingers 86 a of different lengths.

[0066] Each horizontal finger 86 a is an elongated rod with arectangular cross-section. Each horizontal finger 86 a includes a baseportion and an extended portion. The base portion affixes to horizontalwedge belt 84 c such that the elongated dimension of horizontal fingers86 a is approximately horizontal. All horizontal fingers 86 a,regardless of overall length, have similarly shaped base portions. Theextended portion extends horizontally away from horizontal wedge belt 84c. Horizontal fingers 86 a vary in the lengths of their extendedportions. The lengths of the extended portions of horizontal fingers 86a are comparable to the lengths of the extended portions of fingers 54.Furthermore, horizontal fingers 86 a within a given horizontal wedge 86are ordered similarly to fingers 56 within a wedge 50, that is, in orderof increasing length.

[0067] Each horizontal finger 86 a has a pushing tip opposite the baseportion, comparable in form and function to pushing tip 56 of finger 54.

[0068] The relative position of adjacent horizontal fingers 86 a canchange when horizontal wedge belt 84 c flexes. The horizontal fingers 86a are movable, such that when a portion of horizontal wedge belt 84 ccontaining adjacent horizontal fingers 86 a travels around horizontalidle wheel 84 a or horizontal drive wheel 84 b, the horizontal fingers86 a roll through the 180° arc described by the perimeter of each wheel,after which the horizontal fingers 86 a are inverted relative to theircounterparts on the opposite side of horizontal wedge belt 84 c.

[0069] Horizontal wedge belt 84 c includes a timing belt comparable inform and function to timing belt of wedge belt 40. Horizontal fingers 86a are bolted to horizontal wedge belt 84 c.

[0070] Horizontal fingers 86 a are formed UHMW (ultra-high molecularweight) plastic. Metal bolts 62 through the base of the finger rigidlyaffix the finger to horizontal wedge belt 84 c.

[0071] Horizontal wedge belt 84 c is supported between horizontal idlewheel 84 a and horizontal drive wheel 84 b such that portions not incontact with wheels 84 a or 84 b are substantially planar.

[0072] As with wedge profile conveyor 14, wedge profile conveyor 84includes a frame that is movable relative to infeed conveyor 12 withhand cranks. A human operator can adjust the distance between wedgeprofile conveyor 14 and infeed conveyor 12. In particular, thisadjustment changes the relationship of pushing face of horizontal wedge86 to offload edge 70.

[0073] In use, wedge profile conveyor 84 selects groups of bottles andtransfers the groups off infeed conveyor 12 over offload edge 70 in amanner comparable to wedge profile conveyor 14. In particular, while incontact with bottles 18, the interaction with bottles of horizontalwedges 86 is similar to that of wedges 50.

[0074] In alternative embodiments, wedge profile conveyor 84 could havemore than three horizontal wedges 86.

[0075] In alternative embodiments, horizontal wedge 86 could be flexiblewithout including fingers 86 a, for example by including a series ofhinged segments.

[0076] In alternative embodiments, horizontal wedge belt 84 c couldinclude a different sort of belt, for example an endless loop oftabletop chain.

[0077] Referring now to FIG. 6, in an alternative embodiment,three-pulley wedge conveyor 88 transfers groups 24 of bottles 18 offinfeed conveyor 90 and toward mass flow conveyor 16. Wedge profileconveyor 84 separates bottles 18 into groups of two or more.

[0078] Three-pulley wedge conveyor 88 includes idle wheel 88 a,intermediate wheel 88 b, drive wheel 88 c, and wedge belt 88 d. In formand function, idle wheel 88 a and drive wheel 88 c are comparable toidle wheel 46 and drive wheel 44 of wedge profile conveyor 14,respectively. Wedge belt 88 d loops around each of idle wheel 88 a,intermediate wheel 88 b, and drive wheel 88 c. Wedge belt 88 d isotherwise comparable to wedge belt 40. Three-pulley wedge conveyor 88includes three wedges 50 attached to wedge belt 88 d.

[0079] Intermediate wheel 88 b is arranged between idle wheel 88 a anddrive wheel 88 c such that when viewed from above, wedge belt 88 d formsan approximate triangle. Wedge belt 88 d flexes when in contact withintermediate wheel 88 b, such that intermediate wheel 88 b divides theportion of wedge belt 88 d that faces oncoming bottles 18 into twosubstantially planar portions. The region between intermediate wheel 88b and drive wheel 88 c is comparable to interface region 48.

[0080] Infeed conveyor 90 is comparable in form and function to infeedconveyor 12, except that infeed conveyor 90 lacks curve 38. As describedwith regard to idle wheel 46, intermediate wheel 88 b can impart amoment arm to fingers 54 of a wedge 50. A finger in motion on wedge belt88 d as it rounds intermediate wheel 88 b can slap bottles that arewithin reach.

[0081] In use, three-pulley wedge conveyor 88 selects groups of bottlesand transfers the groups off infeed conveyor 90 over an offload edgecomparable in form and function to offload edge 70. In particular, whilein contact with bottles 18, the interaction with bottles by wedges ofthree-pulley wedge conveyor 88 is similar to that of wedge profileconveyor 14.

[0082] Referring now to FIG. 7, fingers 54 have an L-shaped profile whenviewed from the side. FIG. 7 shows side views of examples of alternateshapes for fingers in wedge 50: namely, a solid rectangle finger 92, aflag outline finger 94, and a U-shaped finger 96. Each such finger has abase 92 a, 94 a, or 96 a, respectively, through which it is bolted towedge belt 40. Each such finger also has a pushing tip 92 b, 94 b, or 96b, respectively, which functions in use like pushing tip 56 of finger54. That is, it contacts bottles 18 and forms a portion of pushing face52 of wedge 50. For fingers 62, 64, and 96, FIG. 7 shows both a shortestexample and a longest example, in terms of extension away from wedgebelt 40.

[0083] In described embodiments, fingers 54, 86 a, 92, 94, and 96 areeach cut from UHMW plastic by a high-pressure jet of water.

[0084] Solid rectangle finger 92 is a single slab, approximaterectangular when viewed from the side.

[0085] The profile of flag outline finger 94 is largely rectangular,with the addition of a lower extension 94 c along pushing tip 94 b. Theinterior of flag outline finger 94 is cut away, which reduces weight,for example relative to a solid rectangle finger 92 of comparable outerdimensions.

[0086] U-shaped finger 96 has multiple pushing tips 96 b. In use, forbottles 18 of sufficient height, U-shaped finger 96 contacts bottles 18with both pushing tips 96 b.

[0087] In described embodiments, wedge belt 40 is a timing belt. Inalternative embodiments, wedge belt 40 could be another kind of endlessloop, for example a tabletop chain.

[0088] In described embodiments, infeed conveyor 12 is an endless loop,but in alternative embodiments, infeed conveyor 12 could be another kindof transporter of articles, for example a series of motorized rollers.Likewise, in described embodiments, mass flow conveyor 16 is an endlessloop, but in alternative embodiments, mass flow conveyor 16 could beanother kind of transporter of articles, for example a series ofmotorized rollers.

[0089] In described embodiments, mass flow conveyor 16 transportsbottles 18 into a cooler. In alternative embodiments, mass flow conveyor16 could transport bottles 18 to another destination, for example atunnel pasteurizer or a packing machine. Also, in described embodiments,mass flow conveyor 16 is slightly more than 10 feet wide. In alternativeembodiments, mass flow conveyor 16 could be narrower or wider, forexample 2, 4, 6, 8, 12, 14, or 16 feet wide, or more.

[0090] In described embodiments, upper surface 36 is inclined towardwedge profile conveyor 14 at an angle of one or two degrees. Inalternative embodiments, upper surface 36 could be horizontal, i.e., notinclined, or inclined at an angle of less than one degree.Alternatively, upper surface 36 could be inclined toward wedge profileconveyor 14 more steeply, for example at an angle of 5 degrees or more.

[0091] In described embodiments, each finger 54 is less than half aswide as a bottle 18. In alternative embodiments, fingers 54 could bewider relative to bottles 18, for example, 50% as wide, 75% as wide,equally as wide, 125% as wide, and so forth. Moreover, in describedembodiments, fingers 54 are L-shaped when viewed from the side.Referring now to FIG. 7, in alternative embodiments, fingers 54 could beC-shaped 54 b, E-shaped 54 c, or flag-shaped 54 d when viewed from theside. A finger 54 could have multiple pushing tips 56.

[0092] In described embodiments, wedge 50 includes fingers 54 that areseparable. In alternative embodiments, wedge 50 could be substantiallyundivided, for example manufactured of a flexible material that allowswedge 50 to flex around a wheel without flaring apart.

[0093] In described embodiments, wedge belt 40 has three wedges 50. Inalternative embodiments, wedge belt 40 could include more than threewedges 50, for example four wedges, or five, or more.

[0094] In described embodiments, dead plate 26 has an upper surface thatinclines away from offload edge 70 at an angle of six to seven degrees.In alternative embodiments, dead plate 26 could have a differentinclination or no inclination at all. For example, dead plate 26 couldincline away from offload edge 70 at an angle of 1, 2, 3, 4 or 5degrees. Alternatively, dead plate 26 could incline away from offloadedge 70 at an angle of 8, 10, 12, 15, or 20 degrees or more. Moreover,dead plate 26 is optional. In alternative embodiments, articles may betransferred directly from infeed conveyor 12 to mass flow conveyor 16.

[0095] In described embodiments, infeed direction 8 is substantiallylinear over the portions of the infeed conveyor 2 that are next to themass flow conveyor 3. However, in alternative embodiments, infeedconveyor 2 may be curved. Also, infeed conveyor 2 need not be straightin portions away from mass flow conveyor 3 and wedge profile conveyor 1.

[0096] In described embodiments, mass flow conveyor 3 and an infeedconveyor 2 are approximately coplanar and horizontal. However, inalternative embodiments, mass flow conveyor 3 and an infeed conveyor 2could be tilted from the horizontal.

[0097] Accordingly, other embodiments are within the scope of thefollowing claims.

What is claimed is:
 1. An apparatus, comprising: (a) a first transporterthat transports articles in a line; and (b) a member that separates thearticles in the line into groups and removes the groups from the linewhile the articles continue to be transported.
 2. The apparatus of claim1, wherein the member includes a rotator belt positioned to intersectthe line of articles, to separate the articles into the groups, and toremove the groups from the line.
 3. The apparatus of claim 2, whereinthe rotator belt includes wedges that separate the articles into groupsand that push the groups out of the line.
 4. The apparatus of claim 3,wherein the member includes three wedges.
 5. The apparatus of claim 3,wherein the wedges comprise separated elements extending from therotator belt.
 6. The apparatus of claim 5, wherein the elements are ofdifferent lengths.
 7. The apparatus of claim 5, wherein the wedge hasten of the elements.
 8. The apparatus of claim 3, wherein the wedge hasa face that contacts the articles in the group when the wedge pushes thegroup out of line.
 9. The apparatus of claim 8, wherein each wedgepushes the group off an edge of the transporter, and the face has ashape generally corresponding to the shape of the edge.
 10. Theapparatus of claim 9, wherein the length of the face is between 60% and99% of the length of the edge.
 11. The apparatus of claim 2, furthercomprising a blocking member positioned to obstruct the articles as thetransporter transports the articles.
 12. The apparatus of claim 3,further comprising a blocking member positioned to obstruct the articlesbut not the wedges as the transporter transports the articles.
 13. Theapparatus of claim 2, wherein the transporter has an upper surface forreceiving the articles and the upper surface is inclined toward therotator belt.
 14. The apparatus of claim 1, further comprising areceiving member near the transporter for receiving each removed group.15. The apparatus of claim 14, wherein the transporter has an uppersurface for supporting the articles and the receiving member inclinesaway from the upper surface.
 16. The apparatus of claim 14, wherein thereceiving member comprises a plate.
 17. The apparatus of claim 16,wherein the plate is stationary.
 18. The apparatus of claim 1, furthercomprising a second transporter for receiving and transporting thegroups of articles removed from the first transporter.
 19. The apparatusof claim 18, wherein the first transporter transports the articles in afirst direction and the second transporter transports the groups ofarticles removed from the first transporter in a second direction. 20.The apparatus of claim 19, wherein the second direction is approximatelyorthogonal to the first direction.
 21. The apparatus of claim 1, furthercomprising: (c) a receiving member near the transporter for receivingeach group of articles removed from the first transporter; and (d) asecond transporter for receiving and transporting the groups after thegroups pass over the receiving member.
 22. The apparatus of claim 2,wherein the first transporter is angled at approximately the position atwhich the rotator belt intersects the line of articles.
 23. Anapparatus, comprising: (a) a transporter that transports articles in aline; and (b) a rotator belt including wedges, arranged to intersect theline of articles, that includes wedges that push groups of the articlesfrom the line while the articles continue to be transported in the line.24. An apparatus, comprising: (a) a transporter that transports articlesin a line; and (b) a rotator belt including wedges, arranged tointersect the line of articles, that separate the articles into groupswhile the articles continue to be transported in the line.
 25. A methodof transporting articles, comprising: (a) transporting a line ofarticles in a first direction; (b) simultaneously separating a group ofthe articles from the line and transferring the group of articles out ofthe line while the line continues to be transported in the firstdirection.
 26. The method of claim 25, wherein the articles are selectedfrom the group consisting of bottles, cans, containers, cartons, andloaves.
 27. The method of claim 26, wherein the articles include cans.28. The method of claim 26, wherein the articles include containers. 29.The method of claim 26, wherein the articles include cartons.
 30. Themethod of claim 26, wherein the articles include bottles.
 31. The methodof claim 30, wherein the bottles have a cross-section that issubstantially circular.
 32. The method of claim 31, wherein the bottleshave a diameter of from approximately 0.5 inches to 24 inches.
 33. Themethod of claim 31, wherein the bottles have a diameter of fromapproximately 2 inches to 16 inches in the widest cross-section.
 34. Themethod of claim 30, wherein the bottles have a cross-section that issubstantially rectangular.
 35. The method of claim 25, whereinsimultaneously and transferring includes pushing the articles in asecond direction different from the first direction.
 36. The method ofclaim 35, wherein the second direction is approximately orthogonal tothe first direction.
 37. The method of claim 35, wherein the seconddirection is between approximately 45 degrees and approximately 135degrees, relative to the first direction.
 38. The method of claim 35,wherein transporting the line of articles in a first direction includestransporting the line of articles at a first speed in the firstdirection, and pushing the articles in the second direction includespushing the articles at a second speed in the second direction, thesecond speed having a vector component speed in the first directionapproximately equal to the first speed.
 39. The method of claim 25,further including transferring the groups to a plate.
 40. The method ofclaim 39, wherein for a given transferred group, the articles of thetransferred group arrive at the plate at substantially the same time.41. The method of claim 39, further including transporting a group ofarticles in a third direction such that, for a prior group of articlesthat is transferred before a subsequent group is transferred, the priorgroup and the subsequent group belonging to the groups of articles, theprior group is transported in the third direction before the subsequentgroup.
 42. The method of claim 34, wherein the bottles are transportedshort-side first in the first direction.
 43. The method of claim 42,wherein the bottles are separated and transferred out of the line by awedge that intersects the line, and the depth of the wedge isapproximately the length of the short side.
 44. The method of claim 25,wherein the group of articles is transported in a second direction afterbeing transferred from the line.
 45. The method of claim 44, wherein theline of articles are transported in the first direction at a first speedand the group of articles are transported in the second direction at asecond speed.
 46. The method of claim 45, wherein the first speed isfrom 10 fpm to 400 fpm and the second speed is from 2 fpm to 30 fpm. 47.The method of claim 45, wherein the first speed is at least 5 times thesecond speed.
 48. The method of claim 47, wherein the first speed is atleast 20 times the second speed.
 49. The method of claim 47, wherein thearticles are bottles that have been filled with a beverage and heatedprior to separating the group and transferring the group, wherein thegroup of articles are transported in the second direction into a cooler.50. The method of claim 49, wherein groups of articles are massedtogether as they are transported in the second direction into thecooler.